Driverless transport vehicle with perfectly integrated toothed belt conveyor from MK © MK Technology

"Instead of a chain conveyor, we opted for a two-strand timing belt conveyor," explains Ulrich Klein, sales representative at MK, who supported the project. A toothed belt conveyor is cheaper and requires less maintenance than the originally planned chain conveyor. In addition, the timing belt has a higher grip than the chain. This also means greater stability for the product on the vehicle, even on sharp bends or an abrupt stop, for example during an emergency stop. The ZRF-P 2010 timing belt conveyor from MK was the ideal solution for the project: it can safely carry the maximum load of 160 kilograms and the available drive variants also allow reversing (in both directions) operation.

High degree of automation

"The Maxolution vehicle fleet with the integrated load handling device from MK plays a key role in implementing the Industry 4.0 approach at the site. The high degree of automation makes work much easier for our employees," emphasizes Rainer Neufeld, Corporate Electronics Manager and Project Manager for the AGV fleet in the USA. "The vehicles transport our geared motor kit to various stations over a distance of several kilometers per day. The precise and reliable transfer of the trays with the help of the MK load handling device is very important here."

"There were a few technical challenges with the project," recalls Ulrich Klein. Due to its integration into the vehicle, the motor was not allowed to create any interfering contours on the outside. In addition, a free space had to be left between the two conveyor lines for the protruding output shaft of the gearbox. The motor therefore had to be positioned between the lines underneath the conveyor. Here, the MK designers were able to use a modified MK center drive. "After the initial inquiry, it took us around two weeks to fully specify the conveyor and clarify the installation situation in the vehicle," says Aaron Bronner. "That went really quickly and worked wonderfully. As the MK conveyor also has a modular design, it was easy to adapt for the planned application and integrate into the vehicle."

Because MK uses SEW drive technology as standard, integrating the drive was no problem. The Maxolution experts programmed the control system and coordinated it with the overall system.

Unconventional help

How did Maxolution come to order the conveyors from MK? "It was a nice story," says Aaron Bronner. "We had already bought conveyors from MK for another project. That was over Christmas and had to be realized at very short notice." And because the collaboration on this previous project had worked so well and smoothly, Aaron Bronner turned directly to MK again.

The Maxolution automated guided vehicle system serves as a mobile workbench for the assembly of SEW geared motors. © MK Technology

This comes as no surprise to Ulrich Klein: "We maintain good customer-supplier relationships and always try to be a reliable partner as far as we can. This also includes helping our customers in unconventional ways. Thanks to our strong modular system, we also have the right products for individual customer solutions." In the project to build mobile workbenches for the Lyman site, everything came together - good relationships and the flexibility to quickly adapt the right product to the customer's needs.

Another plus point for the good cooperation is that the MK subsidiary MK North America is within easy reach. This means that MK fitters can carry out maintenance and service on site if required.

Solutions even for spontaneous challenges

Shortly before the conveyor belts were delivered, Maxolution decided to install individual side guides to guide the workpiece carriers. This required additional screw-on points on the conveyor body. Aaron Bronner recalls: "Due to spontaneous changes in the project, the conveyors still had to be adapted. It was really close to the deadline. Fortunately, that wasn't a problem." The open system grooves of the MK aluminum profile system allowed additional brackets to be fitted. Ulrich Klein is convinced by the MK modular system: "It often seems to be just little things, like these additional screw-on points. Yet such small details often make the difference when it comes to quick and easy commissioning."

Installation of the customized toothed belt conveyor ZRF-P 2010 from MK with modified center drive © MK Technology

The timing belt conveyors were delivered to Maxolution and integrated into the vehicles following a joint final acceptance test. There are now 27 driverless transport vehicles in use at the Lyman assembly plant, flexibly serving the workers at the production stations.

Rainer Neufeld: "The new assembly plant at our main site in Lyman is now the flagship in the USA and can be seen as a benchmark for other SEW-Eurodrive plants."

Aaron Bronner continues: "We are already planning another project for another SEW location." It is possible that Maxolution will offer exactly the same vehicles again with the conveyors from MK. "I hope that we can implement the project in exactly the same way again, as the technology for this has already been designed. We know it works and wouldn't have to start from scratch again."

This project shows how classic conveyor technology and modern driverless transport systems together enable more efficient process automation and more individualized production. Projects like these are another milestone for SEW on the road to the smart factory of tomorrow.